RAMJET 502 Engine 12499121 Specifications Specifications Part Number 88962910

RAMJET 502 Engine 12499121 Specifications Specifications Part Number 88962910 Thank you for choosing Chevrolet Performance Parts as your high performance source. Chevrolet Performance Parts is committed to providing proven, innovative performance technology that is truly. more than just power. Chevrolet Performance Parts are engineered, developed and tested to exceed your expectations for fit and function. Visit our website at www.chevroletperformance.com for the Chevrolet Performance Parts Authorized Center nearest you. This publication provides general information on components and procedures that may be useful when installing or servicing a RAMJET 502 engine. Please read this entire publication before starting work. Also, please verify that all of the components listed in the package contents section below were in fact shipped in the kit. The information below is divided into the following sections: package contents, component information, RAMJET 502 engine specifications, installation instructions, additional parts that you may need to purchase, torque specifications, and service parts list. The RAMJET 502 engine is a fully assembled engine. This engine is assembled using brand new, premium quality components. The RAMJET 502 engine is manufactured on current production tooling; consequently you may encounter dissimilarities between this engine assembly and previous versions of the big block V8. In general, items such as motor mounts, accessory drives, exhaust manifolds, etc. can be transferred to a RAMJET 502 engine when installed in a vehicle originally equipped with a big block V8 engine. However, as noted in the following sections, there may be significant differences in the water pump, oil pan, etc., between a RAMJET 502 engine and an older big block V8 engine. These differences may require modifications or additional components not included with this engine. When installing the RAMJET 502 engine in a vehicle not originally equipped with a big block V8, it may be necessary to adapt or fabricate various components for the cooling, fuel, electrical, and exhaust systems. Due to the wide variety of vehicles in which this engine can be installed, some procedures and recommendations may not apply to specific applications. The RAMJET 502 engine is based on the marine electronic, port fuel injection system, and the Chevrolet Performance 502/502 crate engine. The RAMJET 502 engine includes an aluminum intake manifold, fully calibrated Engine Control Module (ECM), wiring harness, all the necessary sensors, distributor, ignition coil, throttle body, fuel rail, and throttle cable brackets. All the gaskets and attaching hardware required for the components you need to install are included in the kit as well. This package is assembled using brand new, premium quality components. The RAMJET operating system is a very advanced fuel injection control system that uses a minimum amount of inputs to the engine control module (ECM) for ease of installation. Because of this, there are certain operating conditions that should be understood to ensure proper operation. For example, due to the variety of applications and uses, this system has no provisions for vehicle speed input, transmission range input (automatic) or clutch pedal input (manual transmission) to the ECM. If the Throttle Position Sensor (TPS) is reading a closed throttle with engine running, the engine controller has no way of determining if it is being driven down the road or idling in Park or Neutral. If the driver operates the engine in a way that pulls the engine speed below the desired idle, the normal reaction of the control module is try to keep the engine speed above the minimum RPM by adjusting the Idle Air Control (IAC) and ignition timing. If the driver continues to operate the vehicle in this forced low speed manner, the IAC and spark may continue to climb until it is at maximum. If the load is suddenly taken away (clutch pedal depressed, shifter moved to neutral), the engine speed will be above desired idle. At that point the engine speed will begin to decrease until it gets back down to desired idle speed. To avoid driving under these conditions, shift the transmission to the next lower gear to prevent lugging the engine below the desired idle speed. 1 54

Operating the RAMJET engine at very low engine RPMs and low vacuum conditions is also not desirable from a fuel economy standpoint. The RAMJET electronic fuel injection system is a speed and air density system ("speed density" fuel management). Sensors provide the ECM with the basic information for the fuel management portion of its operation. Signals to the ECM establish the engine speed and air density factors. The engine speed signal comes from the Ignition Control (IC) module. The ECM uses this information to determine the "speed" or RPM factor for fuel and spark management. The Manifold Absolute Pressure (MAP) sensor contributes the density factor. As intake manifold pressure increases, the vacuum decreases. The air density in the intake manifold also increases as additional fuel is needed. The MAP sensor sends this pressure information to the ECM, and the ECM increases the amount of fuel injected, by increasing the injector pulse width. As manifold pressure decreases, the vacuum increases, and the amount of fuel is decreased. These two inputs, MAP and RPM, are the major determinants of the air/fuel mixture delivered by the fuel injection system. The remaining sensors and switches provide electrical inputs to the ECM, which are used for modification of the air/fuel mixture, as well as other ECM control functions, such as idle control. This package is designed to provide a completely calibrated fuel injection system for the 502/502 crate engine. This system will provide a number of benefits over a carbureted system. These benefits include improved driveability, better fuel economy, and increased performance across the entire RPM range. These benefits are a result of the precise fuel and ignition control across the entire RPM range. All of the spark and fuel management functions are handled through the ECM. It is the control center of the fuel injection system. The ECM controls the fuel metering system, ignition timing, idle speed, and on-board diagnostics for engine functions. It constantly looks at the information from various sensors and controls the systems that affect engine performance. The ECM also performs the diagnostic function of the system. It can recognize operational problems and store diagnostic trouble codes, which identify the problem areas to aid the technician in making repairs. Refer to the Big Block RAMJET service manual, part number 88962724, included in this kit, for more information on using the diagnostic function of the ECM. The ECM controls spark advance for all driving conditions. It monitors input signals from the following components as part of its ignition control function to determine the required ignition timing: Ignition Control (IC) module Engine Coolant Temperature (ECT) sensor Manifold Absolute Pressure (MAP) sensor Throttle Position (TP) sensor Knock Sensor (KS) The function of the fuel metering system is to deliver the correct amount of fuel to the engine under all operating conditions. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold, near each cylinder. The ECM looks at inputs from several sensors to determine how much fuel to supply to the engine. The fuel is delivered under one of several conditions, called modes. These modes include starting mode, clear flood mode, run mode, acceleration mode, fuel cutoff mode, and RPM reduction mode. The ECM controls all of these modes. Refer to the RAMJET service manual for more information on the ECM and the characteristics of each mode. It is not the intent of these specifications to replace the comprehensive and detailed service practices explained in the factory service manuals. 2 54

Observe all safety precautions and warnings in the service manuals when installing a RAMJET 502 engine in any vehicle. Wear eye protection and appropriate protective clothing. Support the vehicle securely with jackstands when working under or around it. Use only the proper tools. Exercise extreme caution when working with flammable, corrosive, and hazardous liquids and materials. Some procedures require special equipment and skills. If you do not have the appropriate training, expertise, and tools to perform any part of this conversion safely, this work should be done by a professional. Legal and Emissions Information This publication is intended to provide information about the RAMJET 502 engine and related components. This manual also describes procedures and modifications that may be useful during the installation of a RAMJET 502 engine. It is not intended to replace the comprehensive service manuals and parts catalogs which cover Chevrolet engines and components. Rather, it is designed to provide supplemental information in areas of interest to do-it-yourself enthusiasts and mechanics. This publication pertains to engines and vehicles which are used off the public highways except where specifically noted otherwise. Federal law restricts the removal of any part of a federally required emission control system on motor vehicles. Further, many states have enacted laws which prohibit tampering with or modifying any required emission or noise control system. Vehicles which are not operated on public highways are generally exempt from most regulations, as are some special interest and pre-emission vehicles. The reader is strongly urged to check all applicable local and state laws. Many of the parts described or listed in this manual are merchandised for off-highway application only, and are tagged with the Special Parts Notice reproduced here: Special Parts Notice This part has been specifically designed for Off-Highway application only. Since the installation of this part may either impair your vehicle s emission control performance or be uncertified under current Motor Vehicle Safety Standards, it should not be installed in a vehicle used on any street or highway. Additionally, any such application could adversely affect the warranty coverage of such an on-street or highway vehicle. The information contained in this publication is presented without any warranty. All the risk for its use is entirely assumed by the user. Specific component design, mechanical procedures, and the qualifications of individual readers are beyond the control of the publisher, and therefore the publisher disclaims all liability incurred in connection with the use of the information provided in this publication. Chevrolet, Chevy, the Chevrolet Bow Tie Emblem, General Motors, and Chevrolet are all registered trademarks of the General Motors Company. 3 54

Package contents: Item Description Quantity GM Part Number 1 Engine assembly, 502/502 base 1 12496963 2 Specifications 1 88962910 3 Big Block RAMJET service manual 1 88962724 4 Diagnostic trouble code (DTC) tool 1 12489400 5 Intake manifold, upper 1 12464484 6 Gasket, intake manifold lower to upper 4 12489372 7 Intake manifold bolt, upper to lower 8 12490255 8 Air cleaner assembly 1 12490257 9 Fuel line connector, feed 1 12487372 10 Fuel line connector O-ring, feed 1 22514722 11 Fuel line connector, return 1 12487373 12 Fuel line connector O-ring, return 1 19258137 13 Fuel pressure regulator hose 1 10216948 14 Wiring harness 1 88961968 15 Accelerator/TV cable bracket assembly 1 12489595 16 Accelerator/TV cable bracket bolt 1 12490259 17 Center throttle cable bracket assembly 1 12489596 18 Center throttle cable bracket bolt 2 12490259 19 Throttle control rod 1 12489597 20 Throttle control rod bolt 2 12490260 21 Throttle control rod nut 2 N/A 21 Ignition coil assembly 1 1115491 22 Starter motor 1 19302919 23 Starter motor bolt 2 12338064 24 Oil pump primer 1 N/A 25 PCV valve 1 6487532 26 PCV Valve hose 1 9438373 Component Information: Cylinder Heads: The RAMJET 502 engine comes with aluminum cylinder heads, part number 12363390. These cylinder heads are oval port design with 110cc combustion chambers, 2.25 stainless steel intake valves, and 1.88 stainless steel exhaust valves. Intake Manifold: This kit includes a Chevrolet Performance port fuel injection intake manifold designed especially for the RAMJET 502 engine. This two piece intake manifold is manufactured with bosses for mounting the ECM, the fuel rail, the throttle cable and TV cable brackets as well as vacuum ports. Ignition System: This kit includes a distributor ignition system that is connected to the ECM. The ECM monitors the inputs from various engine sensors, computes the desired spark timing and signals the Ignition Control module in the distributor to adjust timing. 4 54

Water Pump: The RAMJET 502 engine comes with an aluminum, short style water pump, part number 19168602. The pump included with this kit has a standard rotation impeller that is used with conventional accessory drives. Some serpentine belt systems require a water pump with a reverse-rotation impeller. In these instances, install a water pump specified for the original application. Air Cleaner: The RAMJET 502 comes with an air filter designed to provide maximum filtration with minimum airflow restriction. This air cleaner, part number 12490257, will attach to any L98 style throttle body, provided enough clearance exists. RAMJET 502 Engine Specifications: Displacement: Bore x Stroke: Compression Block: Cylinder Head: 502 cubic inches 4.47 inch x 4.00 inch 9.6:1 Nominal Cast iron, four-bolt main caps Cast aluminum, oval port Valve Diameter (Intake/Exhaust): 2.25 /1.88 Chamber Volume: Crankshaft: Connecting Rods: Pistons: Rings: Camshaft: Lift: Duration: Centerline: Rocker Arm Ratio: Timing Chain: Oil Pan: Recommended Oil: Oil Pressure (Normal): 110cc Forged steel Forged steel, 7/16 bolts Forged aluminum Chrome Moly Hydraulic roller tapper.527 intake,.544 exhaust 224 intake, 234 exhaust @.050 tappet lift 104 ATDC intake, 109 BTDC exhaust 1.7:1, stamped steel Single roller design 6 - quart 5W30 Synthetic (After Break-in) 6 psig @ 1000 RPM 18 psig @ 2000 RPM 24 psig @ 4000 RPM Oil Filter: Valve Lash: Fuel: Maximum Engine Speed: AC Delco part # - PF454 1/8 Turn down from 0 (Zero) Premium unleaded - 92 (R+M/2) 5800 RPM Spark Plugs: AC Delco Rapidfire # 4 Spark Plug Gap: 0.040" Firing Order: 1-8-4-3-6-5-7-2 Information may vary with application. All specifications listed are based on the latest production information available at the time of printing. 5 54

Installation Instructions: Fuel Line Connector Installation: The fuel line connectors, part number 12487372 and part number 12487373, need to be installed before the upper intake manifold is installed in order to provide the optimum clearance during installation. The fuel line connectors provide you with an AN#6 fitting on the fuel feed line, and an AN#5 fitting on the return line. If your application utilizes some other type of fuel line fitting, you will need to adapt the connectors accordingly. NOTE: Fuel rail fittings are metric threads that utilize O-ring seals. If you decide to use a different fitting to adapt the fuel rail to the vehicle, make sure that fitting fits the fuel rail correctly. The fuel feed fitting size is 16mm x 1.5. The fuel return size is 14mm x 1.5. 1. Install the fuel feed line connector, part number 12487372, and O-ring, part number 22514722, to the fuel rail. This connector threads into the lower fitting at the rear of the fuel rail. Torque this fitting to 27 Nm (20 ft.lbs.). 2. Install the fuel return line connector, part number 12487373, and O-ring part number 19258137, to the upper fitting at the rear of the fuel rail. Torque this fitting to 27 Nm (20 ft.lbs.). 3. Attach the fuel feed line from your vehicle to the fuel feed line connector (the AN#6 connector). Torque this fitting to 27 Nm (20 ft.lbs.). 4. Attach the fuel return line from your vehicle to the fuel return line connector (the AN#5 connector). Torque this fitting to 27 Nm (20 ft.lbs.). Caution: Before the engine is installed in a vehicle, it needs to be filled with oil and primed. You should add GM Goodwrench 5W30 or equivalent motor oil to your new engine. Check the engine oil level on the dipstick and add accordingly. To prime the engine, first remove the distributor to allow access to the oil pump drive shaft. Note the position of the distributor before removal. Install oil priming tool, available from licensed partner www.factoryperformanceparts.com part number 141-955. Using a 1/2 drill motor, rotate the engine oil prime tool clockwise for two to three minutes. While you are priming the engine, have someone else rotate the crankshaft clockwise to supply oil throughout the engine and to all the bearing surfaces before the engine is initially fired. Reinstall the distributor in the same orientation as it was removed. After the engine has been installed in the vehicle, recheck the engine oil level and add oil as required. Ignition Coil Installation: 1. Attach the ignition coil, part number 1115491, to the firewall of your vehicle in a location close enough to the distributor that the coil wire will reach the center post of the distributor cap. The ignition coil can also be attached to the rear of the cylinder head assembly provided enough clearance exists. 2. Attach the coil at the designated location, and torque the attaching bolts to 22 Nm (16 ft.lbs.). Knock Sensor Installation: 1. Install the knock sensor, part number 10456208, in the boss on the lower right-hand side of the block, just forward of the starter motor. Note: If the knock sensor cannot be installed in this position due to interference with the transmission dipstick for example, it may be installed on the opposite side of the engine. If the knock sensor is installed on the left-hand side of the engine, the wiring harness will have to be modified. Modify the harness by separating the B+ wire from the knock sensor wire. This will allow the knock sensor wire to reach the knock sensor. 2. Torque the knock sensor to 16 Nm (12 ft.lbs.). 6 54

ECM and Wiring Harness Installation: The wiring harness included with the RAMJET 502, part number 88961968, will need to be installed. To ease the installation, all of the connectors have been labeled to identify which component each mates with. This harness installation requires a B+ connection and a fused ignition source. A tachometer output lead is also provided. This fuel injection harness is protected additionally by 3 mini fuses in a waterproof connector in the harness. Circuit protection of the B+ feed in the form of a fusible link is advised. Among the items contained in this kit is an oxygen sensor. The oxygen sensor will monitor the exhaust gas and determine the level of richness or leanness of your engine. It will monitor the aggressive, performance oriented fuel tables in the ECM and trim them ever so slightly in order to optimize performance and driveability. This trimming allows you to operate at a maximum level of efficiency and thereby improve both driveability and fuel usage at the same time. In order to install the oxygen sensor in the exhaust, a weld-in exhaust bung has also been included in this kit. An oxygen sensor and exhaust bung as shown in Figure 1. EXHAUST BUNG OXYGEN SENSOR FIGURE 1 Another item in the kit is an intake air temperature sensor. This sensor acts much like a jet change that you might make on a race engine carburetor at the drag strip. Normally you might increase jet size when the temperature rises. This sensor takes the temperature of the inlet air and makes those "jet changes" electronically to the ECM fuel tables in order to optimize power output and get the best fuel mixture for improved performance and economy. An intake air temperature sensor is shown in Figure 2. INTAKE AIR TEMPERATURE (IAT) SENSOR Installation of the exhaust bung requires welding. If you do not have the required equipment to install the exhaust bung, a qualified local muffler shop or service garage should be capable of completing this step for you. FIGURE 2 7 54

Location of Exhaust Bung Before you begin the installation of the exhaust bung, disconnect the negative battery cable to keep from damaging the ECM or sensors. Carefully inspect the engine and fuel system to ensure there are no fuel leaks in the fuel system. If a leak is found, repair before continuing with the installation. RECOMMENDED BUNG INSTALLATION RANGE The oxygen sensor that will be screwed into this bung will function best in the hottest part of the exhaust system. The closer the sensor is to the engine the better. If you have a cast exhaust manifold, locate the bung in the exhaust pipe downstream from the manifold flange but as close to the flange as possible. If you have headers, install the bung into your collector adapter. For installation into a horizontal exhaust pipe, it is recommended that the sensor be installed with the tip facing downward, pointing to the center of the exhaust pipe. Figure 3 shows the recommended installation angles for a horizontal exhaust pipe. If the selected location for your sensor installation is vertical, there is no recommended installation angle; you will want to ensure the tip of the sensor is pointing to the center of the exhaust pipe. You will also need to be sure that your selected bung location will allow installation and removal of the oxygen sensor. Also, ensure that the sensor and associated wiring will not interfere with other components. Also, verify that the sensor wiring and connectors will not melt due to excessive exhaust heat. Drill a 7/8" hole in the exhaust pipe at your selected location using a hole saw. The room must be well ventilated and you must ensure that there are no gasoline leaks or gasoline fumes anywhere near the room or area of welding. Once the bung is installed, let the weld joint completely cool before installing the sensor. It is also recommended that you tap the bung with a 18mm x 1.50 metric tap to eliminate any distortion that may have occurred during the welding process. FIGURE 3 EXHAUST PIPE Installation of Sensors Install the oxygen sensor into exhaust bung. A coat of anti-seize on the oxygen sensor's threads will ease removal of the sensor when replacement is necessary. The oxygen sensor should be torqued to 20 ft.lbs. The intake air temperature (IAT) sensor should be located in the intake air stream. The thread on the provided sensor is 3/8-18 NPT (National Pipe Thread). Your engine comes with the IAT mounted in the bottom of the upper intake manifold. This is the best location unless you are using a remote air filter with a duct from the filter to the throttle body. If this is the case, you should install the IAT sensor in the duct near the filter. If you plan on welding in threads, a pipe nipple from your local hardware may facilitate the installation. Additionally, some "snap-in" intake sensor are available in a number of configurations. 8 54

Installation of Harness You may need to lengthen or shorten the oxygen and IAT sensor wires. It is recommended that this be done by soldering and sealing your soldered connection with heat shrink. Standard butt connectors are not recommended. 1. Lay the wiring harness along the left-hand side of the intake manifold with the idle air control valve, throttle position sensor, and engine coolant temperature sensor connectors at the front of the engine. 2. Connect the sensors mentioned above to their mating components. 3. Attach the eight fuel injector connectors. 4. Plug the MAP sensor connector into the MAP sensor, located on the left hand side of the intake manifold plenum. 5. Install the ECM connectors. Your ECM connectors on the harness can be identified by the clear or smoke colored alignment keys - J1 - smoke, J2-clear. The outside of each connector on the ECM is labeled J1 or J2. 6. Install the coil wire assembly, part number 12097982. One end attaches to the top of the coil, the other end to the rear of the distributor. 7. Attach the connectors from the harness to the distributor and the ignition coil. 8. Plug in the fuel pump and ignition relays. 9. Attach the knock sensor connector to the knock sensor. Use care in routing the wiring harness to the connector so that the harness will not be damaged by heat from the exhaust system. 10. Attach the B+ lead to the big terminal at the starter. A fusible link should be added at this connection for added protection. 11. Connect the fuel pump leads. The installer must provide a wiring harness from the fuel pump to the leads provided. 12. Connect the ignition lead to the ignition switch and attach the tachometer lead if there is one in the vehicle. 13. On your harness you will notice several different grounds. The grounds must be grounded on separate studs on the engine. Failure to use separate ground studs may result in improper engine performance or ECM failure. 14. You will also notice two tachometer outputs from the harness, tach1 is for a standard negative side of the coil driven tach. Tach2 is for new digital tachometers; this is a 0-12 V square wave output. Select and connect the proper output for your application. 15. Reconnect your battery cable. Upper Intake Manifold Installation: 1. Attach the vacuum hose, part number 10216948, to the connector in the bottom of the plenum. Note: Another fitting will need to be installed in the bottom of the upper intake rear most boss to supply vacuum to the brake booster and any other components needing a vacuum signal. A 3/8 NPT fitting, part number 336018 or equivalent, is recommended for this application. Attach one end of the vacuum line to this second fitting before the upper intake manifold assembly is attached to the engine. 2. Install the four intake runner gaskets, part number 12489372, on the lower intake manifold. 3. Place the upper intake manifold on the lower and attach using seven of the eight upper intake manifold bolts, part number 12490255. Do not install a bolt in the left, rear bolt location. (Note: This bolt will be installed with the rear accelerator/tv cable bracket.) Use care when placing the upper intake manifold onto the lower intake manifold to ensure that the gaskets do not shift out of place. 4. Torque the intake manifold bolts to 14 Nm (10 ft.lbs.). 5. Attach the ends of the vacuum hoses to the fuel pressure regulator and the power brake booster. 6. Connect the MAP sensor wiring harness connector to the MAP sensor. 7. Connect the intake air temperature sensor to the wiring harness. 9 54

PCV Valve Installation: 1. Install PCV valve, part number 6487532, into the grommet in the rocker arm cover on the left-hand side of the engine. 2. Install an oil fill cap/breather into the grommet in the rocker arm cover on the right-hand side of the engine. 3. Attach one end of the PCV hose, part number 9438373, to the PCV valve. Attach the other end of the hose to the lower port on the right hand side of the throttle body. Accelerator and Throttle Valve (TV) Cable Bracket Installation: The RAMJET 502 engine includes throttle and TV cable brackets that will allow you to utilize the throttle and TV cables in most carbureted vehicles. Both the accelerator and TV cable brackets can be adjusted approximately 1/2 fore and aft, which should provide enough adjustment for most any application. 1. Remove the fuel rail bolt nearest to the left, rear runner of the intake manifold. 2. Place the rear accelerator/tv cable bracket, part number 12489595, on the intake manifold so that it rests on the left, rear mounting flange between the upper and lower intake manifolds, and the mounting boss between the two left, rear intake manifold bolts. Install the upper intake manifold bolt and torque to 14 Nm (10 ft.lbs.). Reinstall the fuel rail/bracket bolt and torque to 10 Nm (89 in.-lbs). 3. Place the center cable bracket, part number 12489596, on the mounting boss between the runners on the left-hand side of the intake manifold. The bell crank should be on the outboard side of the engine. 4. Attach the bracket with two bolts, part number 12490259, and torque these bolts to 15 Nm (11 ft.lbs.). 5. Install the TV cable into the lower hole on the rear bracket. Push the housing forward until it snaps into place, fully seated. 6. Attach the end of the TV cable to the mounting stud in the lower arm of the bell crank. 7. Install the accelerator cable into the upper hole on the rear bracket, again pushing the housing forward until it snaps into position, fully seated. NOTE: The bracket may need to be modified slightly to accept the throttle and TV cables for your application. 8. Attach the end of the accelerator cable to the upper arm of the bell crank. Install a cable stud into one of the holes, and attach the cable to that stud. The exact position of the stud may vary depending on your application. 9. Attach the throttle control rod, part number 12489597, to the upper arm of the bell crank, with bolt, part number 9406754, and nut, part number 9411893. The rod should be attached through the front bolt hole in the upper arm of the bell crank. Attach the other end of the rod to the throttle body crank. The bend in the throttle control rod needs to be towards the front of the engine to provide clearance to the plenum and runners. Torque both of these bolts to 10 Nm (89 in.lbs.). 10. Ensure that the system operates freely and smoothly. 11. Adjust the accelerator cable by moving the stud in the upper arm of the bell crank. 12. To adjust the TV cable, depress and hold the metal readjustment tab at the engine end of the cable, move the slider until it stops against the fitting, release the readjustment tab, rotate the throttle lever to its full travel position. The slider must move (ratchet) toward the lever when the lever is rotated to its full travel position. Again, check that the cable moves freely, and recheck after the engine is hot. 10 54

Setting Initial Timing: In order to change base timing on the system, the ECM has to be entered into the service mode using the diagnostic trouble code tool, part number 12489400. The ignition control module (IC module), not receiving voltage on the bypass circuit from the ECM, will go into module mode. This can be accomplished by attaching the DTC tool to the data link connector on the wiring harness. 1. Turn the engine s ignition switch the off position (Engine not running) 2. Place the DTC tool s test switch in the off position and plug the tool into the data link connector on the wiring harness. 3. Start the engine, and place the DTC tool test switch in the on position. The IC module will then go to base ignition timing. At this time, the base timing can be adjusted by turning the distributor. Using a timing light, set base timing at 10 Before Top Dead Center (BTDC), and retorque the distributor clamp bolt. Turn the DTC off. The DTC tool can remain connected to the data link connector in the wiring harness, as long as it is turned off. Start-up and Break-in Procedures 1. After installing the engine, ensure the crankcase has been filled with 5W30 motor oil (non-synthetic) to the recommended oil fill level on the dipstick. Also check and fill as required any other necessary fluids such as coolant, power steering fluid, etc. 2. The engine should be primed with oil prior to starting. Follow the instructions enclosed with the tool. To prime the engine, first remove the distributor to allow access to the oil pump drive shaft. Note the position of the distributor before removal. Install the oil priming tool, available from licensed partner www.factoryperformanceparts.com part number 141-955. Using a 1/2" drill motor, rotate the engine oil priming tool clockwise for three minutes. While you are priming the engine, have someone else rotate the crankshaft clockwise to supply oil throughout the engine and to all the bearing surfaces before the engine is initially started. This is the sure way to get oil to the bearings before you start the engine for the first time. Also, prime the engine if it sits for extended periods of time. Reinstall the distributor in the same orientation as it was removed. 3. Safety first. If the vehicle is on the ground, be sure the emergency brake is set, the wheels are chocked and the car cannot fall into gear. Verify everything is installed properly and nothing was missed. 4. Start the engine and adjust the initial timing (see above). Rotate the distributor counterclockwise to advance the timing. Rotate the distributor clockwise to retard the timing. 5. When possible, you should always allow the engine to warm up prior to driving. It is a good practice to allow the oil sump and water temperature to reach 180 F before towing heavy loads or performing hard acceleration runs. 6. Once the engine is warm, Double check the total advance timing is 32 at 4000 RPM if using the deluxe engine configuration. 7. The engine should be driven at varying loads and conditions for the first 30 miles or one hour without wide open throttle (WOT) or sustained high RPM accelerations. NOTE: The ECM is programmed with a "Green Mode" that limits the maximum RPM during the break-in period. From start up to the end of the first hour the limit is 4000 RPM, for the second hour it is 4500 RPM, and for the third hour it is 5500 RPM. 8. Run five or six medium throttle (50%) accelerations to about 4000 RPM and back to idle (0% throttle) in gear. 9. Run two or three hard throttle (WOT 100%) accelerations to about 4000 RPM and back to idle (0% throttle) in gear. 10. Change the oil and filter. Replace with 5W30 motor oil (not synthetic) and a PF454 AC Delco oil filter. Inspect the oil and the oil filter for any foreign particles to ensure that the engine is functioning properly. 11. Drive the next 500 miles under normal conditions or 12 to 15 engine hours. Do not run the engine at its maximum rated engine speed. Also, do not expose the engine to extended periods of high load. 12. Change the oil and filter. Again, inspect the oil and oil filter for any foreign particles to ensure that the engine is functioning properly. 13. Do not use synthetic oil for break-in. It would be suitable to use synthetic motor oil after the second recommended oil change and mileage accumulation. In colder regions, a lower viscosity oil may be required for better flow characteristics. 11 54

Additional parts that may be needed: Flywheel / Flexplate: Like all big block V8 engines, the RAMJET 502 engine has 3.58 diameter flywheel flange bolt pattern. This engine comes equipped with a 14 diameter flexplate with a 168 tooth ring gear, part number 10185034. If your application requires a flywheel, part number 14096987, should be used. This flywheel is 14 diameter, 168 tooth ring gear, and is a for 11 diameter clutch. Use flywheel bolt part number 12337973 (6 required). Pilot Bearing: You must install a pilot bearing in the rear of the crankshaft if the engine will be used with a manual transmission. The pilot bearing aligns the transmission input shaft with the crankshaft centerline. A worn or misaligned pilot bearing can cause shifting problems and rapid clutch wear. A roller pilot bearing, part number 14061685, is recommended for this engine. This heavy-duty bearing adds an extra margin of reliability to a high performance drivetrain. Oil Pan: The RAMJET 502 engine includes oil pan, part number 10242245. This six-quart pan was originally designed for marine and truck usage and may cause interference problems when installed in certain applications. Check for clearance before installation of the engine. If the sixquart pan will not fit into your application, part number 12495360 is recommended as a substitute. This is a four-quart, right-hand dipstick oil pan, which comes with the gasket, four main cap bolts, oil pump screen, dipstick and tube. Fuel Pump / Fuel Lines / Fuel Filter: The RAMJET 502 engine does not include a fuel pump. The fuel system in your application must be capable of supplying a minimum of 45 gallons per hour of fuel. The operating pressure of the fuel pump must be within the range of 43-55 psi. Proper fuel pressure is essential to the correct operation of the RamJet 502. Below are the specifications for expected fuel pressure under various operating conditions. Idle = Steady Cruise = Wide Open Throttle = 38-40 PSI (262-276 KPA) 40-42 PSI (276-290 KPA) 42-44 PSI (290-303 KPA) An in-tank fuel delivery system from a Chevrolet vehicle is recommended for use with this system. The fuel system from any Chevrolet vehicle originally equipped with a port fuel injection system and a V-8 engine is a possible candidate. Production Chevrolet fuel pumps that would be good a candidate include the Vortec truck fuel pump. Carbureted and Throttle Body Injection fuel delivery systems will not meet the needs of a port fuel injection system. They do not provide enough pressure at the fuel rail. An in-tank fuel system is recommended for a number of reasons. First, a Chevrolet production in-tank system will ensure that no vapor lock issues arise. Vapor lock is a common problem with in-line fuel pumps. In high ambient temperatures the fuel in the fuel line can vaporize. An in-line fuel pump cannot move this vapor at the levels required by the fuel injection system. As a result, the fuel pressure at the fuel rail drops, and a number of problems arise. These problems include a stumble or sag to a worst case of a stall and no start condition. Using a Chevrolet in-tank fuel system will ensure that this problem does not occur on your vehicle. Second, the in-tank fuel delivery system will have a return line plumbed into the fuel sender unit. This return line is required for proper operation of this system. The fuel regulator, mounted at the fuel rail, maintains the correct fuel pressure being fed to the injectors, based on intake manifold vacuum. In general, the fuel pump will supply fuel at a pressure greater than required at the rail. The regulator then bleeds off this extra fuel to maintain the correct pressure. The fuel that is bled off needs to be carried back to the fuel tank, via the fuel return line. Third, the fuel tanks used with in-tank fuel systems have baffles in them. These baffles ensure that the fuel pump will have fuel available as long as a sufficient amount of fuel is in the tank. The baffles keep all of the fuel from collecting at one side of the tank during hard cornering, or at the rear of the tank during hard accelerations. If you are installing this package in a vehicle that was originally equipped with a carburetor, the fuel lines will need to be upgraded as well. The lines must be able to handle the increased pressure required by the fuel injection system. Do not use barbed fittings or worm clamps to secure the pressurized fuel lines. Also, ensure that the rubber lines are removed and replaced with fuel lines of sufficient strength, Aeroquip AQP fuel line hose with a stainless overbraid and AN style fittings for example. Finally, use caution in routing the fuel lines to ensure that the lines are not located too close to the exhaust system and are protected from road debris or obstructions. The fuel filter recommended for use with this system is part number 25171792 (AC #GF626). This filter is a 10-micron filter with 3/8" fittings on each end. The fuel filter should be installed between the fuel tank and the fuel rail, typically located close to the fuel tank. 12 54

502 RAMJET Operating RPM Ranges Thinking about the intended usage of the vehicle you will be installing your RAMJET engine into will allow you to make good decisions on your total vehicle package. To get the most effective usage from your crate engine, you should attempt to design the rest of the vehicle to complement the effective engine RPM range. Consider the weight, gearing (transmission and axle) of the vehicle, as well as the vehicle speeds and geography (hilly or flat) that you will most likely be driving in the majority of the time. The RAMJET 502 engine makes peak horsepower at 5100 RPM. A good rule of thumb would be a highway cruising speed that places the engine at an RPM in the range of 60-70% lower than peak. Using this example would place optimal highway engine speed at 1500-2000 RPMs. Heavier vehicles (over 3500 lbs) would perform better using a combination at the higher end of this range and lighter vehicles (under 3000 lbs) would be better suited near the lower end of this range. Things that impact final gear ratio are: Tire Size Axle Gear Ratio Transmission Gear Ratios (with or without overdrive) Torque Converters (stall speed selection and/or with or without lock up feature) Some handy formulas are included below to help make informed decisions. Insert your numbers into these formulas to help you decide what will work best for your application. Tire Diameter = Measured in inches MPH = Typical highway cruising speed Ratio = Final Gear Ratio (Transmission Gear Ratio multiplied by Axle Ratio) Constant = 336 Final Gear Ratio = (RPM x Tire Diameter) divided by (MPH x 336) RPM = (MPH x Final Gear Ratio x 336) divided by (Tire Diameter) MPH = (RPM x Tire Diameter) divided by (Final Gear Ratio x 336) Tire Diameter = (MPH x Final Gear Ratio x 336) divided by (RPM) For example, using the first formula to estimate Final Gear Ratio: 2000 RPM x 30 Tire Diameter 65 MPH x 336 = 2.74 Final Gear Ratio IMPORTANT: Remember to include overdrive transmission ratios in your final calculation. For example, if using a 4L80E transmission, the overdrive ratio is 0.75. In order to get to 2.74 final gear ratio, you would calculate as follows: 2.74 (Final Gear Ratio) 0.75 (Trans O/D Ratio) = 3.65 (Estimated Axle Ratio) At this point, the estimated ratio you determine may not be a ratio that is readily available. You should then review ratio options higher or lower depending on other factors listed above (personal preference and driving habits, geography, overall average vehicle speed, vehicle final weight, ect ). Remember that the examples given here are strictly for demonstration purposes and your results may vary. The consumer assumes all responsibility for determining actual usage conditions. 13 54

Headers: A RAMJET 502 engine should be equipped with a header exhaust system for maximum performance in applications where a nonproduction exhaust system is legal. All of the calibration development and validation testing was done with a header exhaust system installed on our development engines. Installing production style exhaust manifold may increase back pressure and alter the performance of the system. The recommended header configuration is 2 diameter primary pipes, 36 inches long, with 3 1/2 diameter collectors. Use 3 diameter tailpipes with a balance tube ( H pipe) and low restriction mufflers. Rocker Covers: The RAMJET 502 engine comes equipped with die cast rocker covers, part number 12495488. This package includes two covers, 14 bolts, two grommets, and an oil fill hole cap. Chrome Chevrolet Bow Tie rocker covers are available in a short configuration part number 12342093. Chevrolet performance also offers two different cast aluminum rocker covers, part number 12371244 or 25534323. 12371244 has an as cast, light gray color, while 25534323 is a black, powder coated version of the same cover. When using either the cast aluminum or the tall, chrome rocker covers, ensure that enough clearance exists between the rocker arm cover and the brake booster. Diagnostic and Service Tools: Included with the RAMJET system is a diagnostic trouble code tool. This simple device will allow you to read any diagnostic trouble codes stored in the ECM. If you would like more functionality than the DTC tool can provide, you can purchase a TechMate scan tool. Functionally, this scan tool is similar to a Tech 1 or Tech 1A used at Chevrolet dealerships. It provides real-time sensor information, diagnostic trouble codes, and general system information. To purchase a TechMate scan tool, simply call or write to: Rinda Technologies Inc. 4563 N. Elston Avenue Chicago, IL 60630 (773) 736-6633 14 54

RAMJET 502 Engine Torque Specifications: Camshaft retainer bolt/screw Camshaft sprocket bolt/screw Connecting rod nut Crankshaft balancer bolt Crankshaft bearing cap bolt/screw and stud Crankshaft rear oil seal housing nut/bolt/screw Cylinder head bolt /screw Distributor bolt/screw Engine block oil gallery plug ECM mounting bolt/screw Engine coolant temperature sensor Engine front cover bolt screw Flywheel bolt/screw Fuel pressure regulator bolt/screw Fuel pressure regulator outlet line nut Fuel rail bolt/screw Idle air control valve bolt/screw Ignition coil bracket bolt/screw Intake manifold bolt/screw First pass Second pass Knock sensor MAP sensor bolt/screw Oil filter adapter bolt/screw Oil level indicator tube bolt/screw Oil pan assembly Corner nut/bolt/screw Side rail bolt/screw Oil baffle nut Oil pan drain plug Oil pump bolt/screw to rear crankshaft bearing cap Oil pump cover bolt/screw Oxygen Sensor Spark plug Starter motor bolt/screw Throttle position sensor bolt/screw Throttle body bolt/screw Valve lifter guide retainer bolt/screw Water pump bolt/screw 10 ft.lbs. / 13.5 Nm 21 ft.lbs. / 28 Nm 70 ft.lbs. / 95 Nm (.009 bolt stretch preferred) 74 ft.lbs. / 100 Nm 110 ft.lbs. / 149 Nm 11 ft.lbs. / 15 Nm 65 ft.lbs. / 88 Nm 18 ft.lbs. / 25 Nm 15 ft.lbs. / 20 Nm 106 in.lbs. / 12 Nm 106 in.lbs. / 12 Nm 106 in.lbs. / 12 Nm 74 ft.lbs. / 100 Nm 84 in.lbs. / 9.5 Nm 13 ft.lbs. / 17.5 Nm 88 in.lbs. / 10 Nm 28 in.lbs. / 3.2 Nm 16 ft.lbs. / 22 Nm 10 ft.lbs. / 14 Nm 37 ft.lbs. / 50 Nm 14 ft.lbs. / 19 Nm 55 in.lbs. / 6 Nm 18 ft.lbs. / 25 Nm 106 in.lbs. / 12 Nm 15 ft.lbs. / 20 Nm 106 in.lbs. / 12 Nm 30 ft.lbs. / 40 Nm 15 ft.lbs. / 20 Nm 66 ft.lbs. / 90 Nm 106 in.lbs. / 12 Nm 20 ft.lbs / 27 Nm 15 ft.lbs. / 20 Nm (tapered seat) 35 ft.lbs. / 48 Nm 18 in.lbs. / 2 Nm 11 ft.lbs. / 15 Nm 18 ft.lbs. / 25 Nm 30 ft.lbs. / 40 Nm 15 54

RAMJET 502 Service Parts List: Block Assembly, Engine... 19170540 Plug, Engine Block Core Hole... 88891749 Bearing, Camshaft #1... 12508996 Bearing, Camshaft #2,5... 12508997 Bearing, Camshaft #3,4... 12508998 Bolt/Screw, Crankshaft Bearing... 10106460 Bolt/Screw, Crankshaft Bearing... 10106461 Stud, Crankshaft Bearing Cap... 10224104 Plug, Engine Block Cool Drain... 14084945 Plug, Engine Block Oil Cooler Hole... 14090911 Bearing Kit, Crankshaft #1... 12529885 Bearing Kit, Crankshaft #2,5... 10181306 Bearing Kit, Crankshaft #3,4... 10181307 Seal, Crankshaft #5 Bearing Cap... 6264902 Pin, Cylinder Head Locating... 12558081 Head Assembly, Cylinder (Complete, with Valves)... 12363390 Head Assembly, Cylinder (Machined)... 12363399 Valve, Intake... 12366987 Valve, Exhaust... 12366988 Spring, Valve... 12462970 Retainer, Valve Spring... N/A Shim, Valve Spring... 3875916 Lock, Valve... N/A Seal, Valve Stem Oil... N/A Gasket, Cylinder Head... 12363411 Bolt/Screw, Cylinder Head (Long)... 88960332 Bolt/Screw, Cylinder Head (Medium)... 12367330 Bolt/Screw, Cylinder Head (Short)... 88960334 Washer, Cylinder Head Bolt/Screw... 14011040 Crankshaft... 10183723 Pin, Flywheel Locating... 10046031 Seal Assembly, Crankshaft Rear Oil... 10101164 Deflector Assembly, Crankshaft Oil... 14097040 Nut, Crankshaft Oil Deflector... 9422297 Balancer Assembly, Crankshaft... 10216339 Key, Crankshaft Balancer... 10114166 Bolt/Screw, Crankshaft Balancer... 10126796 Washer, Crankshaft Balancer... 3864814 Flywheel Assembly... 10185034 Gear, Flywheel Ring... 03991408 Bolt/Screw, Flywheel... 3727207 Rod Assembly, Connecting... 19170198 Nut, Connecting Rod... N/A Piston Kit, Piston, Pin and Ring Kit (Standard)... 12533507 Piston Kit, Piston, Pin & Ring Kit (0.030 Oversize)... N/A Ring Kit, Piston (Standard)... 12524293 Ring Kit, Piston (0.030 Oversize)... 12524294 Bearing, Connecting Rod... 10181277 Pan Assembly, Oil... 10240721 Plug Assembly, Oil Pan Drain... 11562588 Gasket, Oil Pan... 19213986 Nut, Oil Pan... 1359887 Bolt/Screw, Oil Pan... 9440224 Indicator Assembly, Oil Level... 12557083 Tube Assembly, Oil Level Indicator... 12550533 Seal, Oil Level Indicator Tube... 274244 Pump Assembly, Oil (With Screen)... 19210599 Cover Assembly, Oil Pump... 10241110 Valve, Oil Pressure Relief... 3860377 Spring, Oil Pressure Relief Valve... 3870399 Pin, Oil Pressure Relief Valve... 12551790 Bolt/Screw, Oil Pump Cover... 11508600 Gasket, Oil Pump Cover... 473396 Shaft, Oil Pump Drive... 3998289 Retainer, Oil Pump Drive Shaft... 3764554 Stud, Oil Pump... 3866604 Pin, Oil Pump Locating... 12554553 Plug, Engine Block Oil Galley... 11609914 Plug, Engine Block Oil Galley... 444776 Plug, Engine Block Oil Galley... 14084945 Plug Assembly, Engine Block Oil Galley... 08654382 16 54

Plug Assembly, Engine Block Oil Galley... 14090911 Valve Assembly, Oil Filter By-Pass... 25013759 Fitting, Oil Filter... 3853870 Cover Assembly, Engine Front... 10230954 Seal Assembly, Crankshaft Front Oil... 10191640 Gasket, Engine Front Cover... 10198910 Pin, Engine Front Cover Locating... 12554553 Bolt/Screw, Engine Front Cover... 10243771 Pump Assembly, Water (With Gasket)... 19168602 Bolt/Screw, Water Pump... 9441560 Bolt/Screw, Water Pump... 9440355 Connector, Bypass Hose... 6272959 Hose, Bypass... 1485552 Clamp, Bypass Hose... 01470030 Camshaft Assembly... 12366543 Retainer, Camshaft... 0168501 Bolt/Screw, Camshaft Retainer... 14093637 Sprocket, Camshaft... 12560176 Sprocket, Crankshaft... 12560177 Bolt/Screw, Camshaft Sprocket... 9424877 Chain Assembly, Timing... 10114177 Rod Assembly, Valve Push (Intake)... 10227762 Rod Assembly, Valve Push (Exhaust)... 10227763 Lifter Assembly, Valve... 17120061 Guide, Valve Lifter... 12551397 Retainer, Valve Lifter Guide... 12551399 Bolt/Screw, Valve Lifter Guide Retainer... 9440224 Plug, Camshaft Bearing Hole... 3999200 Pin, Flywheel Housing Locating... 1453658 Arm Kit, Valve Rocker... 12368082 Nut, Valve Rocker Arm... 3896648 Ball, Valve Rocker Arm... 12556299 Cover Package, Valve Rocker Arm... 12495488 Bolt/Screw, Valve Rocker Arm... 25520079 Gasket, Valve Rocker Arm Cover... 14085759 Cap, Valve Rocker Arm Cover Oil Fill... 15681150 Grommet, Crankcase Vent Tube... 10198941 Grommet, Crankcase Vent Valve... 10198949 Spark Plug Assembly... 19307141 Pin, Transmission Locating... 3736406 Engine Assembly, (Service Partial)... 24502619 Motor Assembly, Starter... 19302919 Bolt/Screw, Starter Motor... 12338064 Manifold Assembly, Intake, Lower... 12464482 Manifold Assembly, Intake, Upper... 12464484 Bolt Kit, Intake Manifold... 12497460 Gasket, Intake Manifold Upper to Lower... 12489372 Gasket Assembly, Intake Manifold... 12366985 Fitting, Intake Manifold Vacuum... 14082470 Body Assembly, Throttle... 17113524 Gasket, Throttle Body... 10105379 Gasket Kit, Throttle Body... 17113178 Cover Kit, Throttle Body... 17112831 Sensor Assembly, Throttle Position... 17106682 Attachment Kit, Throttle Body... 17113098 Bolt/Screw, Throttle Body... 11516344 Air Cleaner Assembly... 12490257 Bracket, Accelerator Cable... 12489595 Bracket, Accelerator Cable (Center)... 12489596 Rod, Throttle Control... 12489597 Valve Assembly, Idle Air Control... 17113188 Seal, Idle Air Control Valve... 17082049 Bolt/Screw Kit, Idle Air... 17113168 Housing Kit, Idle Air Control Valve... 17090995 Injector Assembly, Fuel... 17090919 Seal Kit, O-ring, Fuel Injector... 19178978 Retainer Kit, Fuel Injector... 17112633 Rail Assembly, Fuel Injection... 17120039 Bolt/Screw, Fuel Injection Rail... 9440033 Regulator Assembly, Fuel Pressure... 19245527 Bolt/Screw, Fuel Pressure Regulator... 11561767 Seal Kit, Fuel Pressure Regulator... 17113199 17 54

Hose Assembly, Fuel Pressure Regulator Vacuum... 10216948 Hose, Fuel Line Feed... 12487372 Hose, Fuel Line Return... 12487373 Housing Kit, Distributor... 10475771 Pin, Distributor Ignition Pick Up... 454666 Cap, Distributor... 19166099 Bolt/Screw, Distributor Cap... 10469669 Shaft, Distributor... 10491354 Rotor, Distributor... 10477219 Module Assembly, Distributor... 10482830 Bolt/Screw, Distributor... 10469668 Pole Piece, Distributor Pick Up... 10469667 Coil, Distributor Pick Up... 10470794 Retainer, Distributor Ignition Pick Up... 10493403 Gear, Distributor Shaft... 10493532 Pin, Distributor Gear... 456652 Washer, Distributor Shaft Thrust... 1977937 Washer, Distributor Shaft... 1965864 Gasket, Distributor... 10108445 Clamp, Distributor... 10096197 Bolt/Screw, Distributor... 9440169 Sensor Assembly, Knock... 10456208 Coil Assembly, Ignition... 1115491 Sensor Assembly, Map... 12569240 Seal, Map Sensor... 1635948 Bolt/Screw, Map Sensor... 11509665 Module Assembly, Engine Control... 88962718 Sensor Assembly, Engine Coolant Temperature... 15326386 Sensor Assembly, Manifold Air Temperature... 25036751 Filter Assembly, Fuel... 25171792 Harness Assembly, Fuel Injection System Wiring... 12499117 Connector, Fuse... 12102746 Fuse Assembly, Wiring Harness... 12092079 Connector, Relay-Fuel Pump... 15306045 Relay Assembly, Fuel Pump... 12177233 Connector, Relay-Ignition... 15306045 Shield, Distributor Ignition Pick Up... 10496783 18 54

French Caractéristiques techniques du moteur RAMJET 502 12499121 Numéro de pièce des caractéristiques techniques 88962910 Nous vous remercions d'avoir choisi Chevrolet Performance Parts comme source de haute performance. Chevrolet Performance Parts s'est engagée à offrir une technologie de rendement éprouvée et novatrice qui est réellement... beaucoup plus que de la puissance. Les pièces de Chevrolet Performance Parts ont été conçues, élaborées et mises à l'essai de manière à dépasser vos attentes de réglage précis et de fonction. Visitez notre site Web à l'adresse www.chevroletperformance.com pour connaître le centre Chevrolet Performance Parts autorisé de votre région. La présente publication offre de l'information d'ordre général sur les composants et les procédures pouvant s'avérer utile lors de la pose ou de l'entretien du moteur RAMJET 502. Veuillez lire en entier la présente publication avant de commencer à travailler. Veuillez également vérifier que tous les composants énumérés dans la section Contenu de l'ensemble ci-dessous ont été envoyés avec la trousse. L'information ci-dessous est divisée dans les sections suivantes : contenu de l'ensemble, renseignements sur les composants, caractéristiques techniques du moteur RAMJET 502, instructions d'installation, pièces supplémentaires que vous devez peut-être acheter, spécifications de couple et une liste de pièces de rechange. Le moteur RAMJET 502 est un moteur complètement monté. Ce moteur est monté au moyen de composants neufs de première qualité. Le moteur RAMJET 502 est fabriqué sur l'outillage de production actuel ; par conséquent, il est possible de rencontrer des dissemblances entre ce moteur et les précédentes versions du gros bloc V8. En général, les éléments tels que les fixations du moteur, les entraînements d'accessoires, les tubulures d'échappement, etc. peuvent être transférés sur un moteur RAMJET 502 lorsqu'il est monté sur un véhicule équipé à l'origine d'un moteur V8 gros bloc. Toutefois, comme il est indiqué dans les sections suivantes, il pourrait y avoir des différences importantes au niveau de la pompe à eau, du carter d'huile, etc., entre le moteur RAMJET 502 et un moteur V8 à gros bloc plus ancien. Ces différences peuvent nécessiter des modifications ou des composants supplémentaires non compris dans ce moteur. Lors du montage d'un moteur RAMJET 502 sur un véhicule non équipé à l'origine d'un V8 à gros bloc, il peut être nécessaire d'adapter ou de fabriquer divers composants pour le refroidissement, le carburant, les systèmes électriques et les systèmes d'échappement. En raison du grand nombre de véhicules sur lesquels le moteur peut être monté, certaines procédures et recommandations peuvent ne pas s'appliquer aux applications particulières. Le moteur RAMJET 502 est basé sur le système d'électronique nautique d'injection de carburant et le moteur Chevrolet Performance 502/502. Le moteur RAMJET 502 comprend un collecteur d'échappement en aluminium, un module de commande du moteur (ECM) entièrement étalonné, un faisceau de câbles, tous les capteurs nécessaires, un distributeur, une bobine d'allumage, un papillon, une rampe de carburant et des supports de câbles de papillon. Tous les joints et le matériel de fixation nécessaire pour les composants à installer sont inclus dans le kit. Cet ensemble est assemblé avec des composants neufs de première qualité. Le système d'exploitation RAMJET est système de commande d'injection de carburant très avancé qui utilise un minimum d'entrées dans le module de commande du moteur (ECM) pour faciliter la pose. Pour cette raison, il est nécessaire de comprendre certaines conditions de fonctionnement pour assurer le bon fonctionnement. Par exemple, en raison des nombreuses applications et utilisation, ce véhicule n'a aucune disposition pour l'entrée de la vitesse du véhicule, l'entrée de la gamme de boîte de vitesses (automatique) ou l'entrée de la pédale d'embrayage (boîte de vitesses manuelle) vers l'ecm. Si le capteur de position du papillon (TPS) est fermé pendant que le moteur est en marche, le module de commande du moteur n'est pas en mesure de déterminer si le véhicule roule sur la route ou s'il roule au ralenti en position de stationnement (P) ou au point mort (N). Si le conducteur commande le moteur de façon à baisser le régime du moteur sous le ralenti souhaité, la réaction normale du module de commande est de maintenir le régime moteur au-dessus du régime minimal en réglant la régulation de l'air de ralenti (IAC) et le calage de l'allumage. Si le conducteur continu à commander le moteur à ce «faible régime forcé», l'iac et l'allumage peuvent continuer à grimper jusqu'à ce qu'ils atteignent le maximum. Si la charge est subitement retirée (pédale d'embrayage enfoncée, levier de vitesse au point mort), le régime du moteur sera supérieur au ralenti souhaité. À ce point, le régime du moteur commence à diminuer jusqu'à ce qu'il atteigne le régime de ralenti souhaité. Pour éviter de conduire dans ces conditions, passer la boîte de vitesses au rapport inférieur suivant pour éviter de «forcer» le moteur à tourner sous le régime de ralenti souhaité. 19 54

French Faire tourner le moteur RAMJET à très bas régimes moteurs et à faible dépression n'est également pas souhaitable du point de vue de l'économie de carburant. Le système d'injection de carburant électronique RAMJET est un système à régime et densité d'air (gestion de carburant «régime densité»). Les capteurs fournissent à l'ecm les renseignements de base pour la portion gestion de carburant de son fonctionnement. Les signaux envoyés à l'ecm établissent les facteurs de régime moteur et de densité de l'air. Le signal de régime moteur provient du module de commande d'allumage (IC). L'ECM utilise ces renseignements pour déterminer le facteur de «régime» pour la gestion du carburant et de l'allumage. Le capteur de pression absolue de la tubulure d'admission (MAP) fournit le facteur de densité. À mesure que la pression de la tubulure d'admission augmente, la dépression diminue. La densité de l'air dans la tubulure d'admission augmente également lorsque la demande de carburant augmente. Le capteur MAP envoie les renseignements sur la pression à l'ecm, qui augmente la quantité de carburant injecté en augmentant la durée d'impulsion d'injecteur. À mesure que la pression dans la tubulure diminue, la dépression augmente et la quantité de carburant diminue. Ces deux entrées, MAP et régime, sont les déterminants principaux du mélange air/carburant fourni par le système d'injection carburant. Les capteurs et contacteurs restants fournissent les entrées électriques à l'ecm, qui sont utilisées pour la modification du mélange air/carburant, ainsi que pour d'autres fonctions de commande de l'ecm, comme la commande de ralenti. Cet ensemble est conçu pour fournir un système d'injection de carburant entièrement étalonné pour le moteur 502/502. Ce système offre différents avantages par rapport à un système carburé. Parmi ces avantages, on compte une manœuvrabilité améliorée, une économie de carburant accrue et de meilleures performances dans l'ensemble de la plage de régimes moteurs. Ces avantages sont possibles grâce à la commande de carburant et d'allumage précise dans toute la plage de régimes moteurs. Toutes les fonctions de gestion d'étincelles et du carburant sont assurées par l'ecm, qui est le centre de contrôle de ce système d'injection de carburant. L'ECM commande le système de mesure du carburant, le calage de la distribution, le régime de ralenti et les diagnostics embarqués relatifs aux fonctions du moteur. Il surveille constamment l'information provenant des différents capteurs et commande les systèmes qui ont une incidence sur le rendement du moteur. L'ECM exécute également la fonction de diagnostic du système. Il peut reconnaître les problèmes de fonctionnement et mémoriser des codes d'anomalie, qui cernent les zones problématiques pour aider le technicien à effectuer les réparations. Se reporter au manuel de réparation du moteur à gros bloc RAMJET, numéro de pièce 88962724, inclus dans la présente trousse, pour de plus amples renseignements sur l'utilisation de la fonction de diagnostic de l'ecm. L'ECM commande l'avance à l'allumage dans toutes les conditions de conduite. Il surveille les signaux d'entrée des composants suivants dans le cadre de sa fonction de commande d'allumage pour déterminer le calage de l'allumage requis : Module de commande d'allumage (IC) Sonde de température du liquide de refroidissement (ECT) Capteur de pression absolue de la tubulure d'admission (MAP) Capteur de position du papillon (TP) Capteur de cognement (KS) La fonction du système de mesure de carburant est de fournir la bonne quantité de carburant au moteur dans toutes les conditions fonctionnement. Le carburant est amené au moteur au moyen d'injecteurs de carburant individuels montés dans la tubulure d'admission, à proximité de chaque cylindre. L'ECM surveille les entrées de nombreux capteurs pour déterminer la quantité de carburant à fournir au moteur. Le carburant est fourni sous l'une de différentes conditions, appelées «modes». Ces modes incluent le mode de démarrage, le mode d'inondation, le mode de fonctionnement, le mode d'accélération, le mode de coupure de carburant et le mode de réduction de régime. L'ECM contrôle tous ces modes. Se reporter au manuel de réparation RAMJET pour de plus amples renseignements sur l'ecm et les caractéristiques de chaque mode. Ces caractéristiques techniques ne sont pas destinées à remplacer les pratiques d'entretien complètes et détaillées expliquées dans les manuels de réparation d'usine. 20 54